Bill Morgan aka Red Chili

[Red_Chili]

I have put a lot of work in to my 1987 4Runner, which I’ve affectionately named "Red Chili II". You may be wondering about the II at the end of that moniker, and as it suggests, there was at one time a "Red Chili I". The original Chili was a 1990 4Runner that I had outfitted with a 4" IFS lift, 33" BFG MT tires, and rear air locker. Red Chili I met an untimely end in the spring of 2002 though, when it was totalled by a Ford Explorer that ran a red light.

Fortunately neither my family nor I had been hurt and I decided to turn my misfortune into opportunity. I wanted another vehicle that he could comfortably drive for long distances from my Littleton home to trails in Moab and other distant locations. At the same time, the seat time that I spent in Red Chili I had whet my appetite for more difficult trails. To this end I purchased a bone stock 1987 4Runner that was lighter and less expensive than the original Chili, and also provided a platform with more potential. The Red Chili I provided some salvage parts that, thanks to Dr. Toyoda's stable designs, would retrofit nicely.


The Red Chili II as it was purchased.


The transformation 3 months later, courtesy Garage Troll Custom Fabrication:


Sadly, shortly after purchase the headgasket failed and the block deck was corroded on the Red Chili II. To get back to running condition, I researched the options (with an emphasis on “quick!”) and chose a Jasper remanufactured 22RE longblock, which came complete with a 3 year 75,000 mile warranty. With the motor problems sorted out and a blank canvas before me, I relied on the experience of Mike Caskey at Off Road Solutions and Brian Ellinger of Front Range Off Road Fabrication to help achieve my goals. The fresh motor and the transmission were left stock to maintain Toyota reliability, but otherwise modifications began at a frantic pace. In other words, I became known to my wife as “that garage troll”.

A Marlin Crawler adapter and 4.7:1 transfer case gear set were used to give me a 223:1 final crawl ratio. A Front Range Off Road crossmember and skidplate protect the built transfer cases and Rocky Mountain Drivelines built CV driveshafts to put the power to the ground. With the gear selection taken care of, I moved on to the suspension.

The stock IFS was removed and replaced with a Toyota solid front axle hung under 4"/6” Alcan front and rear springs with Front Range Off Road Fabrication spring hangers and shackles. I found that the Alcan springs are the key to allowing my rig to remain stable on the street while providing good articulation on the trail. To allow the springs to work to their full potential, 12" travel Rancho RS9000 shocks were used up front with Ford F-250 shock towers and 10" travel RS9000s were bolted up to an Off Road Solutions shock hoop in the rear. The adjustable RS9000s allowed me to firm up the Chili's ride on the road and remedy any need for a sway bar. Well, mostly anywho.

Though gears and suspension articulation will get a rig through most situations, locked differentials are necessary for the hard core trails that I had in mind when building the second Chili. Off Road Solutions assembled an FJ80 High Pinion third member with 5.29 gears and an ARB Air Locker and the 5.29 and ARB V6 third member from the original Chili was used out back to allow the benefits of full spools without the quirky handling. This allows me to drive my Toyota in the winter on Denver's ice roads without the rear of the 4Runner trying to pass the front. It also helps on icy trails with a side slope!

Once the big tasks were taken care of, I turned my attention to other details. All-Pro Off Road Hysteer was added to allow smooth steering. A modified FJ80 pitman arm from Front Range Off Road Fabrication was later added to allow adequate clearance between the pitman arm and tie rod with the front axle moved about 3" forward of the stock position. V6 brake calipers were used with vented rotors and a V6 master cylinder and brake booster in order to assure reliable stopping on twisty Rocky Mountain roads. SR5 bucket seats and an SR5 center console were added to the interior to make it more comfortable on long trips. 4crawler Off Road Rocksliderz and "Bill-customized" Rockstomper bumpers were bolted to the truck in order to keep the sheetmetal straight and fend off any more errant Explorers, or parking lot soccer-moms. 35" Goodyear MT/Rs keep the bumpers and sliderz off the ground and provide excellent traction with a smooth, quiet ride. And despite all of the upgrades, a Warn M9000 winch was added to the front of Red Chili II just in case I get in over my head.

I woiks so's I can get me truck to woik like dis:


With the help of friends, I’ve achieved my goal of creating a comfortable, capable backcountry vehicle. Not one to sit back and just enjoy, I continued on my list of upgrades that include an R151F transmission, Can-Back soft top, on board air, and finally a 3.4L motor from a 1996 4Runner (many thanks to Mike Caskey of Off Road Solutions for doing the motor swap cleanly and very reliably!). As if that list was not long enough, much of my free time is now scheduled to help my son Justin modify his 1988 Toyota pickup so that he can keep up with me on the trails.

Bill's son Justin following his father's lead. Yeah, like THAT ever happens!


So what do I value most? My fidelity to my Lord, my family, and the conviction that we are to be in this wonderful place as stewards and caregivers, as well as people fully immersed in this wonderful creation. And to help others learn to find a similar way to be at home on this planet. To that end, being a 4x4 Club Land Use Coordinator, sponsoring trails, dualsport motorcycling, hunting, and just being in the woods with friends just makes perfect sense.

Thanks for the visit!!

[Evrgrnmtnman]

What happened to the Red Chili ll to get all wrinkled? Any pics?

[Red_Chili]

Yup, check the tech section. She's gettin' a new body and a new look.

[Red_Chili]

[Red_Chili]

The Chili continues to evolve. Who says armor has to be ugly?